Distributor cap and rotor combination with completely removable stationary electrode and broad contact face movable electrode



Nov. 24, 1.970 F. .1. MORAY 3,542,976 DISTRIBUTOR CAP AND ROTORCOMBINATION WITH COMPLETELY REMOVABLE STATIONARY ELECTRODE AND BROADCONTACT FACE MOVABLE ELECTRODE Filed Aug. 18, 1967 2 Sheets-Sheet 1INVIZNTOR. 1 0F557 r]; M0191) BY WA) NOV. 24, 1970 MQRAY 3,542,976

DISTRIBUTOR CAP AND ROTOR COMBINATION WITH COMPLETELY REMOVABLESTATIONARY ELECTRODE AND BROAD CONTACT FACE MOVABLE ELECTRODE Filed Aug.18, 1967 v INVENIOR. #06557 J MOP/1V A rroeA/EV United States Patent US.Cl. 200-24 12 Claims ABSTRACT OF THE DISCLOSURE The cap and rotorelectrodes have overlapping electrode faces of large area, such asintenfitting grooves and flanges, interfitting cups and cylinders andopposed facing plates which facilitate current transfer. Thedistribu'tor cap electrodes can be solid or of sheet structure. TheWires can be attached to terminals integral with the distributor capelectrodes. Alternatively, terminals on such wires can snap into socketsin the cap electrodes. The wire ends can be secured to the terminals orelectrodes by lugs crimped against the wire ends or such wire ends maybe inserted into sockets of the electrodes or terminals.

Conventional internal combustion engine ignition systems have nottransmitted electric current efiiciently from the ignition coil to thespark plugs of internal-combustion engines which has been one of thefactors responsible for inefiicient eng'me operation. Such inefliciencyresulted from insufficient opposing areas at gaps in the secondarycircuit across which current passes.

It is a principal object of the present invention to provide adistributor structure for reducing the number of gaps in the secondarycircuit and for improving the transfer of electricity across unavoidablegaps, such as from the distributor cap to the rotor, by increasing theelectrode area at opposite sides of such gaps, for producing an ignitionspark of higher intensity energy.

The result of such improved electrode and electrodeconnection structureis to decrease leakage of high-voltage electricity to ground and providea more intense spark across the spark plug gaps so as to causecombustion of the fuel in the engine cylinders to be completed morequickly. Also the sparks are more uniform from cylinder to cylinder. Asa result, the noise and vibration of the engine is reduced, the engineproduces more power and it operates more economically.

A further object is to prevent corona leakage from the distributor capto ground through the conventional capretaining spring.

FIG. 1 is a central vertical transverse section through a preferred typeof distributor cap and rotor combination,

' a terminal and electrode unit being shown in exploded relationship,and FIG. 2 is a detail section taken on line 22 of FIG. 1.

FIG. 3 is a top perspective of a wire terminal and electrode structureshowing the parts in exploded relationship.

FIG. 4 is a fragmentary central vertical section through an alternativetype of rotor structure.

FIG. 5 is a central vertical section through an alternative type of sideelectrode structure and FIG. 6 is a top perspective of a portion of suchelectrode structure.

FIG. 7 is a top perspective of a fragmentary portion of an electrode andFIG. 8 is a central vertical section throuhg an electrode utilizingstructure of the type shown in FIG. 7.

FIG. 9 is a transverse section through such structure taken on line 99of FIG. 8.

FIG. 10 is a detail vertical section through a portion of a sideelectrode structure of a difierent form.

FIG. 11 is a central vertical section through a distributor cap androtor combination, a terminal and electrode unit being shown in explodedrelationship, of a type different from that illustrated in the precedingfigures.

FIG. 12 is a fragmentary vertical section through a different type ofterminal structure.

FIG. 13 is a central vertical section through another type of electrodestructure. FIG. 14- is a transverse section taken on line 14-14 of FIG.13.

FIG. 15 is a detail vertical section through another form of sideelectrode structure.

FIG. 16 is a side elevation of still a different form of terminal andelectrode, with parts broken away, and FIG. 17 is a transverse sectionthrough such terminal taken on line 1717 of FIG. 16.

FIG. 18 is a central vertical section through another type of terminal.

FIG. 19 is a transverse section through still a different terminal.

FIG. 20 is a fragmentary side elevation of a portion of a terminalshowing another type of structure.

FIG. 21 is a transverse section through a terminal showing still anothertype of structure.

The distributor base 1 and cap 2 may be of the type conventionally usedfor automotive purposes, such 'as automobile engines, except for thestructure provided for receiving the supply and distribution wires andtransferring electricity between them. In order to provide a secure andeffective connection between a supply or distribution wire and adistributor cap electrode, a terminal 3 may be provided into which theend of a wire 4 and its insulation 5 can be inserted, as indicated inFIGS. 1, 2 and 3. The wire end can be placed in position betweenwireengaging lugs *6 and such lugs can be crimped toward each other topinch the end of wire 4 tightly between them by inserting suitable toolsthrough apertures 7 in the opposite sides of the terminal 3. To solderthe connection the tools may be heated.

Such terminal can be inserted into the appropriate bore of thedistributor cap by sliding the terminal axially of such bore, in whichbore a metal liner 8 has been installed. One side of such liner has akeyway 9 for receiving a projection 9 of the terminal constituting akey. Interengagement of the projecting key 9 in the keyway 9 will insurethat the terminal 3 is positioned in the proper rotative relationship inthe particular distributor cap before in which it is inserted. Eachterminal can be secured in its bore by a spring leaf detent 10 engagingin a recess 11 in the liner 8. The engagement of such detents andrecesses will, of course, not hamper appreciably intentional withdrawalof a wire and its terminal from a bore of the distributor cap.

It is preferred that the terminal and the electrode for each wire beformed as an integral structure. One type of construction, according tothis principle, is utilized for the central supply wire in FIG. 1. Inthis figure the electrode 12 is formed simply as a tubular cylindricalextension of the terminal 3 so that when the terminal is inserted fullyinto the central bore of the distributor cap, the electrode will projecta substantial distance downward below the inner surface of the cap intothe electrode cup 13 mounted in the distributor rotor 14 on the upperedges of supporting fins 15 molded integrally with the bottom of therotor cavity. Preferably, the cup 13 is of annular channel shape havingan inner upstanding cylindrical wall 13' of sheet structure theprincipal faces of which are parallel to and concentric with the axisabout which the rotor rotates and the inner wall of which is spaced fromthe outer wall of the cup so that the cylindrically tubular stationaryelectrode 12 fits down into the annular cup spaced approximatelyequidistantly from the outer cup wall andthe inner cup wall 13',providing facing areas generally parallel to therotors axis.

From the electrode cup 13 a conductor strip 16 extends. radially outwardalong the arm of the distributor rotor to which such strip is secured by.a split rivet 17, the head of which is embedded in the molded plasticmaterial of which the distributor rotor is made. The outer end of suchstrip is turned upwardly to form an electrode flange 18 of sheetstructure including a narrow top edge joiningopposite upright broad sidefaces which are substantially parallel to the axis about which the rotorrotates. The opposite faces of this flange are in opposed facingrelationship to the opposite sides of a slot 19 in each distributor capside electrode 20 through which the rotor electrode flange passesedgewise as the rotor rotates. Engagement of the keys 9 in the key'ways9 of the side terminal assemblies will maintain the slots 19 orientedcircumferentially of the distributor cap so that the rotor electrodeflange can pass through the slots in such fashion.

More effective transfer of electricity may be effected if the electrodesare of solid construction rather than being of sheet metal construction.In the type of structure shown in FIGS. 1 and 3, the side electrodes 20are shown as being of cylindrical shape with the slots 19 being cut intheir lower ends. Their upper ends are reduced to form a plug 21 of asize to fit within the hollow cylindrical end of a terminal 3. Thereduction in size be tween the lower and upper portions of such sideelectrodes corresponds to the exterior and'interior dimensions of thetubular end 12' of the terminal 3 so that such tubular end can fit overthe electrode plug 21 and abut the shoulder 22 at its base. Such tubularterminal end 12' and electrode plug 21 can be bonded together to form anintegral structure such as by soldering or a copper-brazing procedure.Consequently, when the terminal 3 of a side distribution wire 4 'ispulled out of the distributor cap 2, not only the terminal 3 but alsothe electrode 20 will be withdrawn from the distributor cap.

The alternative type of central supply-electrode structure shown in-FIG.4 includes the same type of hollow cylindrical distributor cap supplyelectrode 12, as shown in FIG. 1, but in this instance the electrodecould, if desired, be of solid structure. The central rotor electrode13', in this instance, is formed simply as a tube 13" on the end of therotor arm conductor strip 16 into which the distributor cap electrode 12fits in overlapping relationship. It will be evident that there is stilla large area of closely adjacent overlapping electrode faces betweenwhich electricity can flow from the distributor cap supply electrode 12to the distributor arm conductor electrode 13", although the opposedtransfer area of the electrodes is considerably less than in thestructure shown in FIG. 1 The modified type of side distributor capelectrode shown in FIGS. and 6 also provides an overlapping electrodetransfer area considerably less than afforded by the structure of FIGS.1 and 3, but the area is still much "greater than in conventionaldistributor structures. In this construction; the overlapping electrodetransfer area is ing the slot 19 to provide electrode surfaces oppositeboth sides of the rotor electrode flange. The electrode can ,be mountedin a terminal 3 in the manner explained in .connection with FIGS. 1 and3 so that the electrode would be integral with the terminal.

a supply or distribution wire is shown in which the wire end 4 would beattached directly to an electrode instead of being attached to aterminal which, in turn, is attached to an electrode. In this instance,a wire-receiving socket 24 is formed integral with the reduced end 21 ofthe electrode. The upper end of such tube has a flared opening25 tofacilitate reception of the. wireend. Suchtube can be crirnped onto thewire end through openings 7' in the opposite sides of the terminal 3',if desired, or an aperture 26 may be provided in one side of the tubethrough which solder cairbe' supplied to bond the wire end to the socket24. The electro'd eusingfthis type of 'wire' attachmentcould be either acentral' electrocle or a side electrode. If it were a central electrode20" of'solid type, as shown in FIG.'8, a cavity.27 could be provided inits lower'end to save' metal and't'o enable such an electrode tobe'lused With an electrode of-the annular cup type, such as 13,13shownin FIG. 1, if desired. Alternatively, of course, such an electrodecould be used with the type of electrode 13", as shown in FIG. 4.

In FIG. 10 the same type of distributor cap side electrode Z3 asdescribed in connection 'witli'FIGS. 5 and 6 is shown, but in thisinstance the. construction ofthe rotor 14 is modified so that theconductor strip 16,.is mounted higher than in the types shown in: FIGS.1.to 5 In this instance, the end of the. arm-conductor strip1 is-bentdownward to form an end flange 18 disposed in overlaping relationshipalongside the distributor cap side electrode 23, both surfaces beinggenerally .parallel tothe rotors axis.

; -;Th e"distributor cap 2 can be held on thedistributor body 1 inconventional fashion by 'providing'a metal rein; forcing ring 2-.encircling the lower edge of the distributor cap. A locating pin 28projects inward from the ring 2' at a position to fit "into aregistering notch 29 in the upper edge'of the distributor base. The capcan=then be secured into-place by at least one," and preferably three,lock screws 30 threaded through the metal -ring;2. so that theinner-,end of the screw or,-.serews will engage; in v a retaining recessor recesses 31. Such lock screws canb e held in place by --a plasticpellet 32 receivedina cavity in the screw thread to prevent itfrom-becomingrloosened ad t y- 1; -j .5.

In FIG. 1'1 an'alternative-.type of terminal construc tion is shown inwhich the wire terminalsareseparable from the distributorcap electrodesinstead jof thosetwo components being} integral, as discussed inconnection with FIGS. 1 to 10. It should be understood, however,

= that the electrode structure 'shownlin FIGS. 1,3; 4, 5,6,

, face relationship for transmissionof'electricitys'fhe eleceration ofthe structure'.=. f .r 'In'-'FIG.*"11"all'of the-distributorcap..-.electrode .structrode areas are stated-"to be =generally-para1lel:to-Jthe rotors axis of rotation because it will .bei-evidentflthat suchsurfaces might be inclined to a greater or lesserextent relative to therotors axis -without alterin pthe'opr tures are'shown as being solid.Thus, the sideelctrode's 20' are of the bifurcated oraslottedtype,*sucli as shown in FIGS. 1' and 3, and'the central electrodec33isofthe solid cylindrical type generally likerthat' shown in FIG. 8. Thedifference in construction between-the-distributorof FIG; 1and-the'distributor"of'FIGl 1l"resides principally the separability of*the': .wire" terminals" and such :electrodes and the permanent mountingof th-elec'trodes in the'distribu'tor cap'inste'ad of such electrodesbe'in gii/ith- InFIGS. 7, 8 and 9, another type of connection for 36 onsuch terminal being engaged in an annular groove 37 in the liner portionof the electrode. In order to provide good electrical conduction betweensuch terminal 35 and the liner 34, in which it is inserted, the fitbetween such terminal and such liner should be quite snug.

The central electrode 33 could fit into a rotor electrode 13" of thetype shown in FIG. 4, if desired. In FIG. 11, however, the cup electrode38 is shown as having a bottom in it, although a scavening hole 39 isprovided in such bottom through which dust particles may fall to keepthe cup bottom clean. A hollow 40 can be provided in the solid electrode33 to save some metal, while preventing dirt and moisture from enteringthe distributor cap; or, alternatively, the electrode structure shown inFIG. 8 could be used in which the cavity opens downward, but still amoisture barrier for the lower end of the terminal-receiving socket isprovided.

In FIG. 12 a dilferent arrangement for securing a terminal is separatefrom or integral with the electrode. In this instance, the upper end ofthe terminal has a flange 41 which fits on a seat 42 formed by the upperend of the liner, the neck 43 of the distributor cap bore has a femalethread 44 with which the male thread 45 of a securing collar 46 canengage. Rotation of such securing collar will cause the interengagedthreads to draw the inner end of such collar against flange 41 to pressthe terminal firmly into the distributor cap and hold it in lace.

p The electrode of FIG. 13 can be used with a terminal of the type shownin FIG. 1. The wire 4 is shown in this instance, however, as' beingreceived in 'a tube 24, such as illustrated in FIG. 7. The electrode20'. can then be secured to a terminal 3, as shown in'FIG. 8. A carbonbutton is fitted slidably in the downwardly opening cylindrical cavity27. In this construction, the lower end 27' of the electrode 20" can berounded and shortened to provide a greater space between its lower endand conductor strip 16 in rotor 14. Such conductor strip can besupported on insulating ribs or fins 15 upstanding from the bottom ofthe rotor cavity. The carbon'button or plunger 47 is urged downward by aspring 48 to assure good electrical contact between the plunger and theconductor strip. The lower end of such spring can be secured to aprojection on the upper end of the plunger and the upper end of thespring can be flared to secure thespring in the cavity 27.

The side electrode in the arrangement of FIG. 15 can either'be integralwith the terminal as shown in FIG. 1 or separable from the terminal asshown in FIG. 11. The lower end of the electrode 20' is formed as aflattened projection 23 similar to the projection 23 shown in FIGS. and6, but in this instance the radially inner and outer sides aresubstantially flattened or concentric about the rotors axis. The arm ofrotor 14 has a shelf 14 projecting from the lower portion of its end tosupport a channelshaped electrode 18" formed on the end of therotorconductor strip 16. The depression between the sides of suchchannel is of a width sufficient to receive closely the electrode 23'projecting downward from the distributor The electrode and terminalstructure shown in FIGS. 16 and 17 is best adapted for use in adistributor con struction where the terminal and the electrode areintegral in each instance. The terminal 3" has a key 9', as shown inFIGS. 1 and 3, but only a single side aperture 7". The reduced upperportion 21 of the electrode 20", such as shown in FIG. 8, can be fittedinto the lower end of the terminal and be bonded to it. In the upper end49 of such electrode is a socket 24 adapted to receive the end of aconnecting wire. Pressure can be inserted through the aperture 7" ontothe side of the electrodes upper end 49 to crimp such electrode endagainst the wire or the'wire end can be soldered in place. In the lattercase, an aperture 26', as shown in FIG. 17, can be provided 6 in theside of the socket 24' through which solder can be supplied.

FIG. 18 shows an electrode and terminal arrangement providing a wire endsocket 24 with a flared opening 25 generally like that shown in FIGS. 7and 8. The terminal 3' can have apertures 7' in its opposite sides, asdescribed for FIG. 8. In this instance, however, instead of theelectrode being of solid construction, as shown in that figure, theelectrode 50 is of shell or tubular structure having an upper reducedportion 51 which fits into and is bonded to the lower end of theterminal 3'. This type of electrode is similar to the hollow cylindricalelectrode 12 of FIGS. 1 and 4 and can be used in installations of thosetypes.

The electrode structure of FIG. 19 can be like that of FIG. 8 or 18. Inthese latter figures, however, a tool of special construction would berequired to crimp the wirereceiving socket 24 tightly against the wire.By adding bosses 52 to the opposite sides of the wire-receiving socket24, use of such a special tool is made unnecessary. Structure of thistype enables the jaws of ordinary pliers to be moved through theopposite apertures 7' of the terminal 3' into engagement with suchbosses for squeezing the tube 24 into flattened shape pressed againstthe wire in the socket.

FIG. 20 shows a terminal structure for holding the insulation of asupply or distribution wire as well as the wire end. The terminalotherwise may be of the type shown in FIGS. 1 and 3, for example. Inthis instance, three or more longitudinal slots 53 extend inward fromthe upper end of the terminal 3 to form tabs 54 between them. The endsof these tabs can be bent inward to bite into the insulation.

Where the wire insulation 5 is smaller than the interior of a terminal 3or where it is desired to clamp the insulation in a manner differentfrom that accomplished by the construction of FIG. 20, the terminal canbe creased longitudinally at locations spaced circumferentially. Thus,in FIG. 21 the grooves 55 located at an angu lar spacing of are formedby pressing the terminal inward locally to provide internal longitudinalribs pressing against the wire insulation. The types of constructionshown in FIGS. 20 and 21 can be utilized either with terminals of thetype shown in FIGS. 1 and 3, for example, or with terminals of the typeshown in FIG. 11.

It will be understood that for any particular distributor variousstructural features described above can be selected, but usually itwould not be desirable to make one peripheral terminal integral with itsperipheral from its peripheral electrode and another peripheral terminalseparable from its peripheral electrode in the same distributor. Itwould not be objectionable, however, to have all of the peripheralterminals integral with their respective peripheral electrodes and thecentral terminal separable from its electrode.

I claim:

1. In an automotive distributor including a body, a rotor in the body,means mounting the rotor for rotation about an axis relative to thebody, a movable electrode carried by the rotor and stationary electrodescarried by the body and arranged in cooperative relationship to themovable electrode, the improvement comprising the movable electrodehaving an electricity conducting portion of sheet structure including anarrow edge joining opposite broad side faces and disposed with one ofits broad side faces generally parallel to the axis about which therotor rotates, and at least one of the stationary electrodes having abroad face generally parallel to the axis about which the rotor rotatesand disposable in axially overlapping, closely adjacent face-to-facerelationship to said broad side face of said movable electrode sheetstructure disposed generally parallel to the rotors axis of rotationwhen such movable electrode broad side face is in registry with saidstationary electrode broad face but spaced radially therefrom, fortransmission of high voltage electricity between such closely adjacentbroad faces of said electrodes through the intervening gap.

L 2 The'combination defined in claim 1, in which one of the electrodesincludes a collar coaxial with the rota tive axis of the rotor, andanother electrode has a cylin- 'drical portion received within andspaced radially from said collar, said collar and said cylindricalportion being relatively rotatable. j

I 3. The combination defined in claim 2, in which the cylindricalelectrode portion has a solid end.

4. The combination defined in claim 2, in whichthe cylindrical electrodeportion has a tubular open end.

. 5. The combination defined in claim 4, and an inner wall locatedconcentrically within and connected to the collar and forming therewithan annular trough into which the tubular open end of the cylindricalelectrode portion projects in radially spaced relation both to thecollar and to said inner wall. l I

6. The combination defined in claim 1, in which one of the electrodeshas an arcuate slot concentric with the rotor axis and opening axially,and a cooperating electrode, has a blade element movablecircumferentially through said slot in radially spaced relationship tothe walls thereof by rotation of the rotor.

7. The combination defined in claim 6, in which the cooperatingelectrode having the blade element is stationary and the electrodehaving the channel-shaped slot is rorated by 'the rotor.

8. The combination defined in claim 6, in which the electrode having thechannel-shaped slot is stationary and the cooperating electrode havingthe blade element is ro tated by the rotor.

9. In an automotive distributor including an interiorly hollow body, arotor in the interior hollow of such body, means mounting the rotor forrotation about an axis relative to the body, a movable electrode carriedby the rotor and stationary electrodes carried by the body and arrangedin the interior hollow of the body in cooperative relationship'to themovable electrode, the improvement comprising one of the stationaryelectrodes being removable from the body, a terminal integral with saidremovable stationary electrode, and a wirevinte'grally connected to saidterminal, said removable stationary electrode, said terminal and saidwire forming an integral structure, the distributor body having a boretherethrough between its exterior and its interiorhollow' of a size forreception'of 'said removable stationary electrode and said terminalintothe exterior end of said bore and for axial movement through said bore adistance sufficiently great to slide said stationary electrode out ofthe interior end of said bore into a position projecting therebeyond forcooperation with the movable electrode, said bore further being of asize for withdrawal of said stationary electrode and said terminaltherefrom by reverse sliding of said electrode and terminal outwardthrough said bore. I a 10. The combination defined in claim9, in whichthe removable stationary electrode is the central electrode andcooperates with the movable electrode carried by the rotor. 1? 11. Thecombination defined in claim 9 and lugs on the terminal engageable withopposite sides of the wire.

12. The combination defined in claim 9 and means releasably'securingthe'termin'al in a predetermined position in the bore distributor body.1 a

References Cited UNITED STATES PATENTS 1,267,671 5/1918 Lang. 2,347,0194/1944 Arthur 20019 2,464,533 3/1949 Shearer 20019 XR 3,001,035 9/1961Butts 200 -19 2,482,997 9/1949 Anderson 200 155.); 2,721,911 10/1955Patla 200 -X 2,760,016 8/1956 Kandoign et al. 200 .153 X 2,876,3033/1959 Alford zoo-153x 3,062,928 11/1962 Machado ZOO- -11 X 3,107,33410/1963 Harges ZOO- 153,18 X

Y 1 FOREIGN PATENTS 455,747: 4/ 1949 Canada.

539,631 4/1957 Canada. 7 "1,095,568 I 6/1955 France.

' 693,383 7/1953 Great Britain.

ROBERT K. SCHAEFER,'Primary Examiner R. A. VANDERl-IYE, AssistantExaminer I j U.'s. C1. X.R. 200166,28;123--146.5

mg UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No-Dated 24,

Inventor(s) Forest J Moray It is certified that error appears in theabove-identified patent and that said Letters Patent are herebycorrected as shown below:

Column 8, line 15, after "9 insert a comma; line 17,

after "9" insert a comma; line 1.9, cancel "born distributor body" andinsert "distributor body bore-.

more {Mia CiLi'ILED FEB. 9,1971

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